Hard Hat Cushioning Device

ABSTRACT

This improved version of the Hard Hat Cushioning Device is more universal and can be used with virtually any hard hat, construction hat, bump cap, and similar hats designed for protection. The device allows the hat to fit more comfortably and securely and helps to prevent hair breakage while maintaining its decorative style. The cushioning effect reduces the restriction of blood flow to the scalp. 
     The newly added air vents, and specific cotton outer material and inside batting material, improves air flow and circulation, making the hat more comfortable to wear while allowing warm air and perspiration to escape. These new improvements increase the ability of the cushioning device to act as a sweat band. Allowing air flow from inside the hat to the outside allowing for decreased temperature of the overall hat itself.

BACKGROUND OF THE INVENTION

The present invention relates generally to hard hats and more specifically it relates to an improved cushioning device for wearers of hard hats.

DESCRIPTION OF RELATED ART

Hard hats are commonly used by persons working in a multitude of industrial/commercial fields as well as those visiting the facility. At times wearers of hard hats experience discomfort as the internal adjustable leather bands tend to grate against the user's head, irritating the skin and scalp, and cause discomfort. While leather has some give to it, it is generally stiff, uncushioned, and provides poor breathability. These hat bands are particularly uncomfortable with warmer weather or internal plant temperatures, where substantial heat builds up inside the hat and increases the wearer's discomfort, causing the user to perspire around the leather band and increasing the irritation of the skin and scalp. This phenomena also occurs in cooler environments when hard hats are worn for longer periods of time. The longer a hard hat is worn, the greater the internal heat builds up inside the hat and the greater the discomfort the user experiences. It is understandable that present leather hat bands are inadequate at maintaining a satisfactory degree of comfort especially in warmer environments and when worn over longer periods of time.

Another problem associated with the use of traditional hard hats is that it is difficult to set a head band width that firmly holds the hard hat in place. The leather bands tend to cause the user to sweat, at times heavily, which sweat causes the band to get slippery. A sudden movement or downturn of the user head commonly results in the hat falling off. Hair breakage around the sweat band is also a common problem associated with the use of the traditional hard hat. Yet another problem associated with the use of a hard hat is the relatively inflexible leather band tends to cut off blood circulation to scalp.

The use of bandanas and handkerchiefs to wrap around hard hat bands partially addresses the problem. The extra material helps provide a small degree of cushioning and helps absorb some of the sweat generated. However the thin material provides very little cushioning and little protection against sweating. It is also difficult to wrap evenly around the leather hat band as wrinkles and creases are typically formed. Although not commercially available, foam inserts may be used to help with cushioning, but when depressed firmly against the head and scalp, foam would provide little breathability and tend to increase irritation in warmer environments.

In addition to fabrics, many types of miniature fans have been used to improve circulation underneath a hard hat. While they may provide some relief, they obviously provide no cushioning.

The use of my invention USD 374,333 provides excellent cushioning and has been used to assist in the cushioning effect. It wraps around the headband and provides adequate cushioning against the head and scalp. Over time, it too tends to become warm as it prevents air from circulating inside the hard hat. This invention has been made from various combinations of materials and uses Velcro to affix itself to the hat band.

A hard hat cushioning device that overcomes the problems associated with prior art by providing superior cushioning and a means of improving air flow to allow heat and perspiration to escape would be valuable to this trade.

BRIEF SUMMARY OF THE INVENTION

The improved cushioning device of the present invention overcomes the problems associated with prior art. It includes air vents positioned in the band that provide a means for warm internal air to escape along with moisture built up from perspiration. It also includes a batting system that improves breathability thereby improving the ability of moist warm air to escape and be neutralized and dried by the outer air and its temperature.

The present invention substantially improves several important aspects of wearing a hard bat including significant reduction of sweating, thus the band does not get slippery as with prior art leather. The soft, cushioning effect of the batting provides a firm fit onto the users head helping eliminate the problem of the bat falling off when tilted or jarred. The soft disposition of the present invention also helps eliminate hair breakage and reduces the restriction of blood flow to the scalp.

The present invention is preferably made of a breathable cotton fabric with a meshed fabric batting such ½ to ¾ loft. This specific type of batting material accompanied by the outer cotton fabric provides maximum breathability of the cushioning device improving air flow and allowing warm moist air to escape. It also provides superior cushioning for the user and wearer of the hard hat. With a thinner loft to the batting, the overall effectiveness of the present invention as described herein is reduced. Obviously with a thicker loft, it may then become too thick and bulky to obtain an effective fit.

In addition the outer cover and batting combination, a series of vent holes are strategically placed in order to further improve the ability of air to flow in and out of the hard hat while worn. These vents are positioned in a unique location opposing one another to ensure maximum possible air flow. Maximizing this airflow promotes the escape of moisture and/or the drying of perspiration trapped inside the hard hat.

The objectives of the present invention are to provide:

-   1) A hard hat cushion that provides added comfort to the wearer of a     hard hat; -   2) A hard hat cushion that provides air flow; -   3) A hard hat cushion that is not slippery; -   4) A hard at cushion that reduces sweating. -   5) A hard hat cushioning and air flow system; -   6) A cushioning and air flow device that can be decorative; -   7) A hard hat cushioning and air flow system with ventilation; -   8) A hard hat cushioning and air flow system with opposing vents; -   9) A hard hat cushioning and air flow system that allows warm air to     escape; -   10) A hard hat cushioning and air flow system that allows     perspiration to escape; -   11) A cushioning and air flow device that allows warm air inside a     hard hat to escape.

Furthermore, it is an object of this application to illustrate the preferred embodiments and broadly state the methodologies that may be used in order to describe the primary objective being accomplished.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of the inner portion of the present invention illustrating the preferred embodiments and their related elements.

FIG. 2 is a plan view of the outer portion of the present invention illustrating the preferred embodiments and their related elements.

FIG. 3 is a cross-sectional view showing the improved batting component.

FIG. 4 is a perspective view of the present invention attached to a hat band and showing how the present invention provides superior air flow to the inside of the hard hat.

DETAILED DESCRIPTION OF THE INVENTION A. Description of the Present Invention

In FIG. 1 the present invention 10 consists of an inner surface, preferably cotton, and includes a Velcro® like hook closure strip 20 along one edge and a Velcro like loop closure strip 30 along an opposing edge. Four notches 40 a, 40 b, 40 c and 40 d are spaced apart in such a manner to conform to the internal binding supports on the leather head ban used in hard hats.

The hook closure strip 20 and loop closure strip 30 are stitched in place along the out edges illustrated by dashed lines 22 and 32 respectively. This stitching also provides substance and excellent durability to the present invention as it would otherwise be limp and somewhat difficult to attach. While the use of Velcro tends to be ideal, other types of closures may be used such as snaps, hooks, and buttons, but are not practical from the aspect of being easy to use. With the use of Velcro, even if misaligned by the wearer it still remains in place and serves the intended function.

Adjacent stitches, dash lines 22, set just inward from the hook closure strip 20 are five rectangular air vents 50 a, 50 b, 50 c, 50 d and 50 e. Adjacent stitches, dash lines 32, set just inward from the loop closure strip 30 are five rectangular air vents 60 a, 60 b, 60 c, 60 d, and 60 e. As illustrated, the location of the set of air vents 50 a, 50 b, 50 c, 50 d, and 50 e are directly opposite air vents 60 a, 60 b 60 c, 60 d, and 60 e. As will be illustrated in FIG. 4 the alignment of these vents maximizes air flow inside a hard hat that employs the present invention. The vent holes as illustrated herein may be of any number of shapes or types for example round grommets, plastic or metal, button holes round or rectangular, or simple cut slits in any shape. Tests consistently showed that the rectangular air vents positioned as illustrated provide the best results. Likewise, being sewn in with a button hole stitch provides excellent durability without danger of a plastic or metal grommet rubbing against the wearer's head or scalp. The stitched vent holes are also durable throughout many washings unlike grommets.

In FIG. 2 the present invention 10 consists of an outer surface 14, preferably cotton, and is a mirror image of the inner surface illustrated in FIG. 1. While it has no hook closure strip or loop closure strip its integrity is held secure in place by stitches illustrated as dashed lines 22 and 32. Notches 40 a, 40 b, 40 c and 40 d are along one edge with vent holes 50 a, 50 b, 50 c, 50 d, and 50 e and 60 a, 60 b, 60 c, 60 d, and 60 e set adjacent stitches, dashed lines 22 and 32, as also illustrated in FIG. 1.

As illustrated in FIGS. 1 and 2 the outer fabric is plain with no design. It can be appreciated that this fabric may be made in any number of designs and colors, including sports fabrics, fabrics for men or women, and any number of designer patterns. Likewise the thickness or quality may vary depending on the desired quality. Ideally, outer fabric 12 and 14 are a preshrunk cotton so since the batting that will be inserted in between is a polyester material that will not shrink. Using preshrunk cotton on these outer surfaces prevents bunching up of the present invention after washing.

In FIG. 3, the present invention 10 illustrates the superior internal batting 70 sewn between the inner layer surface 12 and the outer surface 14, providing even cushioning throughout and provided maximum breathability throughout as well. While a multitude of types of batting may be used, the preferable type is 100% bonded polyester blend, ½ to ¾ loft. This specification makes the present invention easy to handle, machine washable and non-allergenic. Polyester has superior breathability, strength and durability and helps the band hold its shape. It also resists mold and mildew.

C. Method of Use

In FIG. 4 the present invention 10 is attached to the leather hat band H in a hard hat, the upper edge of which hat band H is defined by dashed lines D. Present invention 10 has been secured by wrapping it around hat band II and matching of the two Velcro surfaces together. As shown, the four notches 40 a, 40 b, 40 c, and 40 d have been positioned about the four hat band attachments B1, B2, (B3 and B4 not shown). The attachment of present invention 10 show how it is adjustably secured at the rear location 16 illustrating the overlapping of the two ends. As illustrated vent holes 50 a, 50 b, 50 c, 50 d, and 50 e (only 50 d and 50 e are shown) are aligned respectively with vent holes 60 a, 60 b, 60 c, 60 d, and 60 e (only 60 a and 60 b are shown). This unique, precise alignment provides for air flow circulation inside the hard hat and the scalp of the wearer to the outside environment illustrated by arrows A. Thus, the hard hat may be worn comfortably with the padding provided and more importantly with the added ventilation provided by the aligned vent holes. In this illustration the ten vent holes provide five aligned ventilation systems but any number may be used. Five tends to provide adequate ventilation, but more (or less) may also be used.

E. Variations

Any number of material types may be used to accomplish similar results; however, what is illustrated herein represents the preferred embodiments. It goes without saying the attachment to a head band may be done with snaps, string ties, buttons and sewn on, instead of Velcro hook and loop fasteners. Likewise the notches may be made in various configurations, as the notches are what make the band of the present invention able to fit most hard hats in commercial use. Made without notches, it wouldn't fit on the user's head evenly, smoothly. While stitching is preferred, it is plausible that other means of affixing the plies is possible.

In summary, the spirit of the present invention provides a breadth of scope that includes all methods of making and using it. Any variation on the theme and methodology of accomplishing the same that are not described herein would be considered under the scope of the present invention. 

1-4. (canceled)
 5. A cover for a suspension hat band comprising: at least one layer of pad material; at least one layer of overlay material significantly encapsulating the pad material; one or more radial cut-outs disposed along at least one edge of the overlay material; multiple vent openings extending through the overlay material; and at least one fastening mechanism for closing the overlay material over the hat band. 